2009 arctic cat 700 h1 700h1 atv service repair manual by 1639701yu

FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2009 Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To service models not included in this manual, please refer to the following publications: â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘ â&#x20AC;˘

2009 Y-12 Service Manual 2009 T-14 Service Manual 2009 DVX 300/250 Utility Service Manual 2009 366 Service Manual 2009 700 Mud Pro Service Manual Supplement

This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol Â&#x201E; NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.

ÂŠ 2008 Arctic Cat Inc. ÂŽâ&#x201E;˘ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

August 2008

TABLE OF CONTENTS Foreword Click on the blue text to go.

Section 1.

General Information/Specifications

Periodic Maintenance

Engine/Transmission

Fuel/Lubrication/Cooling

Electrical System

Drive System

Suspension

Steering/Frame

Controls/Indicators

SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS

TABLE OF CONTENTS General Specifications ............................................ 1-2 Torque Specifications .............................................. 1-3 Torque Conversions (ft-lb/N-m) ............................... 1-6 Tightening Torque (General Bolts) .......................... 1-6 Break-In Procedure ................................................. 1-6 Gasoline - Oil - Lubricant ........................................ 1-6 Genuine Parts ......................................................... 1-7 Preparation For Storage.......................................... 1-7 Preparation After Storage........................................ 1-8

1-1

General Specifications* 400 TRV

H1 Models

CHASSIS

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12

0.35 kg/cm² (5 psi)

Tire Inflation Pressure

MISCELLANY Gas Tank Capacity (rated)

20.8 L (5.5 U.S. gal.)

Rear Drive Capacity

250 ml (8.5 fl oz)**

Front Differential Capacity

275 ml (9.3 fl oz)***

Engine Oil Capacity

3.3 L (3.5 U.S. qt) - Overhaul 2.8 L (3.0 U.S. qt) - Change

0.35 kg/cm² (5 psi)

MISCELLANY Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - TRV/Cruiser

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

275 ml (9.3 fl oz)**

Rear Drive Capacity

250 ml (8.5 fl oz)***

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil Capacity

Engine Oil (recommended)

Arctic Cat ACX All Weather (Synthetic)

2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change

Gasoline (recommended)

87 Octane Regular Unleaded

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic)

Drive Belt Width (minimum)

28.5 mm (1.12 in.)

Brake Fluid

DOT 4

Differential/Rear Drive Lubricant

Taillight/Brakelight

12V/8W/27W

Headlight

12V/37W (2)

500

SAE Approved 80W-90 Hypoid

Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

CHASSIS Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

H2 Models CHASSIS Brake Type

Hydraulic w/Brake Lever Lock and Auxiliary Brake

Tire Size

Front - 25 x 8-12 Rear - 25 x 10-12

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

MISCELLANY Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.)

MISCELLANY

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

275 ml (9.3 fl oz)**

Rear Drive Capacity

250 ml (8.5 fl oz)***

Engine Oil Capacity

3.4 L (3.5 U.S. qt) - Manual 2.5 L (2.6 U.S. qt) - Automatic

Gasoline (recommended)

87 Octane Regular Unleaded

Rear Drive Capacity

250 ml (8.5 fl oz)***

Engine Oil (recommended)

Arctic Cat ACX All Weather (Synthetic)

Engine Oil Capacity

2.8 L (3.0 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Drive Belt Width (Automatic) (minimum)

38 mm (1.33 in.)

Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

Gas Tank Capacity (rated)

24.6 L (6.5 U.S. gal.) 20.8 L (5.5 U.S. gal.) - Cruiser

Coolant Capacity

3.3 L (3.5 U.S. qt)

Differential Capacity

275 ml (9.3 fl oz)**

Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Front Differential/Rear Drive SAE Approved 80W-90 Hypoid Lubricant Drive Belt Width (minimum) 35.6 mm (1.40 in.) Brake Fluid

DOT 4

Taillight/Brakelight

12V/8W/27W

Headlight

12V/27W (2)

* Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads.

1-2

Torque Specifications EXHAUST COMPONENTS Part

Part Bolted To

Exhaust Pipe

Engine

Spark Arrester

Muffler

DRIVE TRAIN COMPONENTS (400 TRV)

Torque ft-lb N-m 20

Part

Part Bolted To

Torque ft-lb

N-m

Engine Mounting Through-Bolt Frame

Front Differential

Frame/Differential Bracket

Output Flange

Rear Flange Output Joint

Pinion Housing

Differential Housing

48 in.-lb

5.5

Engine/Harness Ground Cap Crankcase Screw

Coil (500)*

Frame

Coil (EFI Models)

Air Filter Housing

Differential Housing Cover***

Drive Bevel Gear Nut**

Shaft

Driven Bevel Gear Nut**

Driven Shaft

Lock Collar

Differential Housing

125

169

ELECTRICAL COMPONENTS

STEERING COMPONENTS Steering Post Bearing Housing

Frame

Steering Post Bearing Flange Frame

Lower Steering Bearing Washer Cap Screw***

Steering Post

54 Hub Nut

Shaft/Axle (max)

200

272

Tie Rod End

Knuckle/Steering Post

Oil Drain Plug

Front Differential/ Rear Drive

45 in.-lb

Oil Fill Plug

Front Differential/ Rear Drive

Oil Drain Plug

Engine

BRAKE COMPONENTS Brake Disc*

Hub

Brake Hose

Caliper

Brake Hose

Master Cylinder

Brake Hose

Auxiliary Brake Cylinder 20

Rear Drive Input Shaft/Housing Differential Housing

Master Cylinder (Rear)

Frame

Wheel

Hub

Hydraulic Caliper

Knuckle

Rear Drive Gear Case

Frame

Master Cylinder Clamp

Master Cylinder

Engine Output Shaft**

Brake Pedal Axle

Rear Gear Case Input Flange

Brake Pedal

DRIVE TRAIN COMPONENTS (500 - Manual Transmission)

CHASSIS COMPONENTS Footrest

Frame (8 mm)

Engine (Lower Rear/Front)

Frame

Footrest

Frame (10 mm)

Front Differential

Frame/Differential Bracket

A-Arm (400/500/H1 Models) Frame

Pinion Housing

A-Arm (H2 Models)

Frame

Differential Housing

Knuckle

Ball Joint

Differential Housing Cover***

Differential Housing

Shock Absorber

Frame

Drive Bevel Gear Nut***

Shaft

Shock Absorber

Upper A-Arm

Lock Collar

169

A-Arm

Differential Housing

125

Knuckle

SUSPENSION COMPONENTS (Front)

SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper)

Hub Nut

Shaft/Axle (max)

200

272

Oil Drain Plug

Front Differential/ Rear Drive

45 in.-lb

Oil Fill Plug

Front Differential/ Rear Drive

Frame

Shock Absorber (Upper) (H2 Frame Models)

Shock Absorber (Lower)

Lower A-Arm

Oil Drain Plug

Engine

A-Arm

Frame

Inspection Plug

A-Arm (H2 Models)

Frame

Front Differential/ Rear Drive

Knuckle

A-Arm

Wheel

Hub

Rear Drive Input Shaft/Housing Differential Housing Rear Drive Gear Case Engine Output Shaft**

Knuckle (H2 Models)

A-Arm

48 in.-lb

5.5

Frame

Rear Gear Case Input Flange

* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609

1-3

DRIVE TRAIN COMPONENTS (500 - Automatic Transmission/H1 Models) Part

Part Bolted To

ENGINE/TRANSMISSION (400 TRV)

Torque

Part

Part Bolted To

Torque

ft-lb

N-m

ft-lb

N-m

Engine Mounting Through-Bolt Frame

Clutch Shoe**

Crankshaft

147

199

Engine (TRV)

Engine Cradle

Crankcase

Engine Cradle (TRV)**

Rubber Mount

Clutch Cover/Housing Assembly

Rubber Mount (TRV)

Frame Bracket

Left-Side Cover

Crankcase

Front Differential*

Frame/Differential Bracket

Crankcase Half (6 mm)

Crankcase Half

13.5

Crankcase Half (8 mm)

Crankcase Half

Rear Flange Output Joint

Cylinder Nut

Crankcase Half

Pinion Housing

Differential Housing

Differential Housing Cover***

Differential Housing

Output Flange

Cylinder Head (Cap Screw) Crankcase

Drive Bevel Gear Nut***

Shaft

Differential Gear Case***

Hub

Lock Collar

Differential Housing

125

169

Hub Nut

Shaft/Axle (max)

200

272

Oil Drain Plug

Front Differential/ Rear Drive

45 in.-lb

Cylinder Head (6 mm)

Cylinder

Cylinder Head (8 mm)

Cylinder

Cylinder Head Cover

Cylinder Head

Oil Pump Drive Gear**

Crankshaft

Driven Pulley Nut**

Driveshaft

147

199

Ground Cable

Engine

Output Shaft Flange Nut

Output Shaft

Magneto Rotor Nut

Crankshaft

107

146

Oil Fill Plug

Front Differential/ Rear Drive

Cam Sprocket**

Camshaft

Oil Drain Plug

Engine

Starter Motor

Crankcase

Rear Drive Input Shaft/ Housing

Differential Housing

V-Belt Cover

Crankcase

Wheel

Hub

Valve Adjuster Jam Nut

Valve Adjuster

9.5

Rear Drive Gear Case

Frame

Oil Fitting

Engine

Engine Output Shaft **

Rear Gear Case Input Flange

Oil Pump*

Crankcase

Movable Drive Face Nut**

Clutch Shaft

147

199

Oil Cooler Hose Clamps

Engine/Oil Cooler

30 in.-lb

3.4

DRIVE TRAIN COMPONENTS (H2 Models) Engine Mount (Rear)

Frame

Front Differential

Frame/Differential Bracket

Rear Gear Case

Frame

Pinion Housing

Differential Housing

Differential Housing Cover***

Differential Housing

Lock Collar

Differential Housing

125

169

Hub Nut

Shaft/Axle (max)

200

272

Oil Drain Plug

Front Differential/ Rear Drive

45 in.-lb

Oil Fill Plug

Front Differential/ Rear Drive

Oil Drain Plug

Engine

Wheel

Hub

Rear Drive Input Shaft/ Housing

Differentail Housing

Rear Output Drive Flange

Rear Yoke Flange

Shift Cam Stopper

Shift Stopper

Shift Cam Plate

Shift Cam Shaft

Shifter Housing

Crankcase

Engine Output Shaft**

Rear Gear Case Input Flange

* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609

1-4

ENGINE/TRANSMISSION (500 - Manual Transmission) Clutch Shoe

Crankshaft

127

Clutch Sleeve Hub

Countershaft

Crankcase Half (6 mm)

Crankcase Half

Crankcase Half (8 mm)

Crankcase Half

Cylinder Head (Cap Screw) Cylinder

Cylinder Head (6 mm Nut)

Cylinder

Cylinder Head (8 mm Nut)

Cylinder

Cylinder Head Cover

Cylinder Head

9.5

Left-Side Cover

Crankcase Half

Oil Pump Drive Gear**

Crank Balancer Shaft

Oil Strainer Cap

Strainer

Oil Pump*

Crankcase

9.5

Output Shaft Gear

Output Shaft

Rear Output Shaft

Output Joint

Recoil Starter

Left-Side Cover

Starter Motor

Crankcase

Reverse Cam Stopper Housing

Crankcase

Right-Side Cover

Crankcase

Magneto Rotor Nut

Crankshaft

116

157

Shift Stop Housing

Crankcase

Cam Sprocket**

Camshaft

Starter Cup

Crankshaft

Movable Drive Face Nut**

Driveshaft

Engine Damper

Thermostat Housing

9.5

ENGINE/TRANSMISSION (500 - Automatic Transmission) Part

Part Bolted To

ENGINE/TRANSMISSION (H2 Models) Torque

Part

Part Bolted To

Torque

ft-lb

N-m

Clutch Shoe**

Crankshaft

127

Clutch Shoe**

Clutch Cover/Housing Assembly

Crankcase

Clutch Cover/Housing Assembly Crankcase

Crankcase Half

Crankcase Half (6 mm)

Crankcase Half

Crankcase Lower Cover (6 mm) Crankcase

Crankcase Half (8 mm)

Crankcase Half

Crankcase Lower Cover (8 mm) Crankcase

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head (6 mm)

Cylinder

Cylinder Head (6 mm)

Cylinder

Cylinder Head (8 mm)

Cylinder

Cylinder Head Cover

Cylinder Head

9.5

Driven Pulley Nut**

Driveshaft

110

Ground Wire

Engine

Magneto Cover

Crankcase

Movable Drive Face Nut**

Fixed Drive Face

Oil Pump Drive Gear**

Crank Balancer Shaft

Crankshaft Crankcase Half

ft-lb

N-m

221

300

Cylinder Head (8 mm)

Cylinder

Cylinder Head Cover

Cylinder Head

8.5

11.5

Driven Pulley Nut**

Driveshaft

108

Ground Wire

Engine

Magneto Cover

Crankcase

Oil Filler Cover

Crankcase

Speed Sensor Housing

Crankcase

Output Shaft Flange Nut

Output Shaft

Starter Motor

Recoil Starter

Left-Side Cover

V-Belt Housing

Crankcase

Cylinder

Magneto Rotor Nut

Crankshaft

116

157

Intake Manifold

Cam Sprocket**

Camshaft

13.5

Output Shaft Nut

Output Shaft

Crankshaft

107

145 13.5

Starter Cup

Crankshaft

Rotor/Flywheel Nut

Starter Motor

Crankcase

Cam Sprocket**

Camshaft

V-Belt Cover

Clutch Cover

Clutch Shaft

165

224

V-Belt Cover

Crankcase

Valve Adjuster Jam Nut

Valve Adjuster

9.5

Movable Drive Face Nut**

Oil Pump

Crankcase

9.5

Oil Pump Cover*

Crankcase

Drive Pulley Nut**

Clutch Shaft

110

Oil Strainer Cap

Crankcase

Shift Cam Stopper

Crankcase

Shift Cam Stopper Spring

Shift Cam Stopper

Shift Cam Shaft

ENGINE/TRANSMISSION (H1 Models) Clutch Shoe**

Crankshaft

221

300

Shift Cam Plate

Clutch Cover/Housing Assembly

Crankcase

Shifter Housing

Crankcase

Crankcase Half (6 mm)

Crankcase Half

Output Yoke Nut

Driven Output Shaft

100

Crankcase Half (8 mm)

Crankcase Half

Cylinder Head (Cap Screw)

Crankcase

Cylinder Head (6 mm)

Cylinder

Cylinder Head (8 mm)

Cylinder

Cylinder Head Cover

Cylinder Head

8.5

11.5

Driven Pulley Nut

Driveshaft

108

Ground Wire

Engine

Magneto Cover

Crankcase

Oil Pump Drive Gear**

Crank Balancer Shaft

Output Shaft Nut

Output Shaft

Outer Magneto Cover

Left-Side Cover

Magneto Rotor Nut

Crankshaft

107

145

Cam Sprocket**

Camshaft

13.5

Starter Motor

Crankcase

V-Belt Cover

Clutch Cover

Drive Pulley Nut**

Clutch Shaft

165

224

Movable Drive Face Nut**

Clutch Shaft

165

224

Output Yoke Nut

Driven Output Shaft

100

* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609

1-5

Torque Conversions (ft-lb/N-m)

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

ft-lb

N-m

1.4

35.4

69.4

103.4

2.7

36.7

70.7

104.7

4.1

38.1

72.1

106.1

5.4

39.4

73.4

107.4

6.8

40.8

74.8

108.8

8.2

42.2

76.2

110.2

9.5

43.5

77.5

111.5

10.9

44.9

78.9

112.9

12.2

46.2

80.2

114.2

13.6

47.6

81.6

115.6

117

16.3

50.3

84.3

118.3

17.7

51.7

85.7

119.7

121

20.4

54.4

88.4

122.4

21.8

55.8

89.8

123.8

23.1

57.1

91.1

125.1

24.5

58.5

92.5

126.5

25.8

59.8

93.8

127.8

27.2

61.2

95.2

129.2

28.6

62.6

96.6

130.6

29.9

63.9

97.9

131.9

31.3

65.3

99.3

133.3

32.6

66.6

100.6

134.6

102

100

136

Tightening Torque (General Bolts)

Type of Bolt (Conventional or 4 Marked Bolt)

(7 Marked Bolt)

Thread Diameter Tightening A (mm) Torque 5

12-36 in.-lb

36-60 in.-lb

7-11 ft-lb

16-25 ft-lb

24-48 in.-lb

6-8 ft-lb

13-20 ft-lb

29-43 ft-lb

Break-In Procedure

1-6

A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all prescribed adjustments and tightening of all fasteners.

Gasoline - Oil Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates (either ethanol or MTBE) are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol, 5% methane, or 5% MTBE are acceptable gasolines. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.

! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used.

RECOMMENDED ENGINE/ TRANSMISSION OIL

! CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.

The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 5W-50 oil is acceptable.

ATV0049B

! WARNING Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank.

! WARNING Do not over-fill the gas tank.

Tighten the gas tank cap securely after filling the tank.

Genuine Parts

OILCHARTI

RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives.

! CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.

FILLING GAS TANK

! WARNING Always fill the gas tank in a well-ventilated area. Never add fuel to the ATV gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank.

Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area.

When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.

Preparation For Storage ! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.

Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover. 1-7

! CAUTION

1. Clean the ATV thoroughly.

If the interior of the air filter housing is dirty, clean the area before starting the engine.

2. Clean the engine. Remove the cloth from the exhaust system.

4. On carbureted models, drain the carburetor float chamber.

3. Check all control wires and cables for signs of wear or fraying. Replace if necessary.

5. Plug the exhaust hole in the exhaust system with a clean cloth.

4. Change the engine/transmission oil and filter.

6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 8. On liquid-cooled models, fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 9. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 10. Store the ATV indoors in a level position.

! CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.

Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV.

1-8

5. On liquid-cooled models, check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables.

! CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system.

! CAUTION Connect the positive battery cable first; then the negative.

7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug(s). Clean or replace as necessary.

SECTION 2 PERIODIC MAINTENANCE

TABLE OF CONTENTS Periodic Maintenance Chart.................................... 2-2 Periodic Maintenance.............................................. 2-3 Lubrication Points.................................................... 2-3 Air Filter................................................................... 2-3 Valve/Tappet Clearance (Feeler Gauge Procedure) ................................... 2-4 Valve/Tappet Clearance (Valve Adjuster Procedure) (400/500/H1 Models) ........................................... 2-5 Valve/Tappet Clearance (Valve Adjuster Procedure) (H2 Models).............. 2-6 Testing Engine Compression .................................. 2-6 Spark Plug(s) .......................................................... 2-7 Muffler/Spark Arrester ............................................. 2-7 Engine/Transmission Oil - Filter - Strainer .............. 2-8 Front Differential/Rear Drive Lubricant .................. 2-10 Adjusting Clutch (500 Manual Transmission) ........ 2-11 Steering Components ........................................... 2-11 Driveshaft/Coupling ............................................... 2-11 Suspension/Shock Absorbers/Bushings ............... 2-11 Nuts/Bolts/Cap Screws.......................................... 2-12 Headlights/Taillight-Brakelight ............................... 2-12 Shift Lever ............................................................. 2-13 Frame/Welds/Racks .............................................. 2-14 Electrical Connections........................................... 2-14 Hydraulic Brake Systems ...................................... 2-14 Burnishing Brake Pads.......................................... 2-15 Checking/Replacing V-Belt (Automatic Transmission)................................... 2-16 2-1

A = Adjust C = Clean D = Drain

Periodic Maintenance Chart

Item Battery

Initial Service Every Every 3 After Break-In Every Month or Months or (First Mo or 100 Day Every 100 Every 300 Mi) Miles Miles I

I = Inspect L = Lubricate R = Replace T = Tighten

Every 6 Every Year Months or or Every Every 500 1500 Miles Miles

Fuses

C I

Air Filter/Drain Tube

Valve/Tappet Clearance

R I

Engine Compression Spark Plug(s)

A I

Muffler/Spark Arrester

R (4000 Mi or 18 Mo) C

Gas/Vent Hoses

Throttle Cable

R R (2 Yrs)

C-L

Carburetor Float Chamber (Carbureted Models) Engine Idle RPM (Carbureted Models)

As Needed

A-R

D* I

Engine-Transmission Oil Level

Engine-Transmission Oil/Filter

Oil Strainer

Front Differential/Rear Drive Lubricant

A R*/R**/R***

R I

Clutch (Manual)

Tires/Air Pressure

Steering Components

V-Belt (Automatic)

Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

Nuts/Cap Screws/Screws

R (4 Yrs) l

A R

R l

Ignition Timing

Headlight/Taillight-Brakelight

Switches

R R

Shift Lever

A-L

Recoil Starter (500)

Handlebar Grips

R R

Handlebar

I I

C-R

Gauges/Indicators

Frame/Welds/Racks

Electrical Connections

Complete Brake System (Hydraulic & Auxiliary)

Brake Pads

Brake Fluid

R (2 Yrs)

Brake Hoses

R (4 Yrs)

Coolant (Liquid-Cooled Models)/ Cooling System

l l I

C L-R

R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

2-2

Periodic Maintenance

Air Filter

This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV.

Use the following procedure to remove the filter and inspect and/or clean it.

NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.

CLEANING AND INSPECTING FILTER 1. Remove the seat; then remove the appropriate reinstallable rivets securing the storage compartment.

NOTE: Critical torque specifications are located in Section 1.

SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Description

p/n

Compression Tester Kit

0444-213

Oil Filter Wrench

0644-389

Tachometer

0644-275

Timing Light

0644-296

Valve Clearance Adjuster

0444-078

CF260A

2. Raise the storage compartment cover; then slide the cover forward and off the compartment. Remove the storage compartment.

NOTE: Special tools are available from the Arctic Cat Service Parts Department.

Lubrication Points It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference.

FI467

A. Throttle Lever Pivot/Cable Ends B. Brake Lever Pivot/Cable Ends C. Auxiliary Brake Cable Ends D. Shift Lever Cable End E. Idle RPM Screw (Carburetor) (If Applicable)

FI468

3. Unsnap the four spring-clip fasteners; then remove the air filter cover. 2-3

CHECKING AND CLEANING DRAINS 1. Inspect the drains beneath the main housing for debris and for proper sealing.

CD675A

4. Remove the air filter element/screen assembly and separate the element from the screen. 5. Fill a wash pan larger than the element with a non-flammable cleaning solvent; then dip the element in the solvent and wash it. NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat.

KX045A

2. Replace any drain that is cracked or shows any signs of hardening or deterioration.

! CAUTION

6. Dry the element. 7. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. Attach the element to the filter screen.

! CAUTION A torn air filter element can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.

8. Clean any dirt or debris from inside the air cleaner. Be sure no dirt enters the carburetor (if equipped). 9. Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter screen down.

The drain to the right is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage.

3. Wipe any accumulation of oil or gas from the filter housing and drains.

Valve/Tappet Clearance (Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the following procedure. 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components). NOTE: On the H2 models, remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine.

2. Rotate the crankshaft to the TDC position on the compression stroke (front cylinder on the H2 models). NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.

CD674

10. Install the air filter housing cover and secure with the retaining clips. 11. Install the storage compartment; then secure with the reinstallable rivets.

2-4

3. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.

! CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.

0.076-0.127 mm (0.003-0.005 in.)

Exhaust

0.152-0.203 mm (0.006-0.008 in.)

NOTE: The seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for this procedure.

VALVE/TAPPET CLEARANCE (500) Intake

0.05-0.10 mm (0.002-0.004 in.)

Exhaust

0.17-0.22 mm (0.007-0.009 in.)

1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components).

VALVE/TAPPET CLEARANCE (H1/H2 Models) Intake

0.1016 mm (0.004 in.)

Exhaust

0.1524 mm (0.006 in.)

(Valve Adjuster Procedure) (400/500/H1 Models)

To check and adjust valve/tappet clearance, use the following procedure.

VALVE/TAPPET CLEARANCE (400) Intake

Valve/Tappet Clearance

CF005 CC007DC

4. On the H2 models, rotate the engine 270° to the TDC position of the rear cylinder; then repeat step 3.

2. Rotate the crankshaft to the TDC position on the compression stroke. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. NOTE: Use Valve Clearance Adjuster for this procedure.

5. Install the timing inspection plug; then on the H2 models, remove the cap screw and install the crankcase end cap. 6. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely.

5. Align the valve adjuster handle with one of the marks on the valve adjuster dial. 6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance.

2-5

NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 8. Place the two tappet covers with O-rings into position; then tighten the covers securely. 9. Install the spark plug; then install the timing inspection plug.

Valve/Tappet Clearance (Valve Adjuster Procedure) (H2 Models)

To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side engine panels must be removed for this procedure.

1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components).

NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. NOTE: Use Valve Clearance Adjuster for this procedure.

3. Place the valve adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. 4. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. 5. Align the valve adjuster handle with one of the marks on the valve adjuster dial. 6. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance. NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. 8. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat steps 4-7 for the rear cylinder. 9. Place the tappet covers with O-rings into position; then tighten the covers securely. 10. Install the spark plugs; then install the timing inspection plug and crankshaft end cap.

CF005

2. Rotate the crankshaft to the TDC position on the compression stroke of the front cylinder.

Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead(s) from the spark plug(s). 2. Using compressed air, blow any debris from around the spark plug(s).

! WARNING Always wear safety glasses when using compressed air. GZ063

2-6

3. Remove the spark plug(s); then attach the high tension lead(s) to the plug(s) and ground the plug(s) on the cylinder head(s) well away from the spark plug hole(s). 4. Attach the Compression Tester Kit. Â&#x201E;NOTE: The engine must be warm and the battery must be fully charged for this test.

5. While holding the throttle lever in the full-open position, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes).

ATV-0051

! CAUTION

PEAK COMPRESSION MODEL

PSI

400

95-115

500

70-85

H1 Models

155-175

H2 Models

75-85 (Front) 120-130 (Rear)

Before removing a spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug.

Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper ignition. Use a feeler gauge to check the gap.

6. If compression is abnormally low, inspect the following items. A. Verify starter cranks engine over at normal speed (approximately 400 RPM). B. Gauge functioning properly. C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Valve not bent or burned. F. Valve seat not burned. Â&#x201E;NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, reattach the gauge, and retest compression.

ATV0052C

When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head.

8. If compression is now evident, service the piston rings (see Section 3).

Muffler/Spark Arrester

Spark Plug(s)

At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure.

A light brown insulator indicates that a plug is correct. A white or dark insulator indicates that the engine may need to be serviced or the carburetor (if equipped) may need to be adjusted. To maintain a hot, strong spark, keep the plug free of carbon.

! WARNING Wait until the muffler cools to avoid burns.

1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester.

2-7

CF105A

ATV-0075

2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen. NOTE: If the screen or gasket is damaged in any way, it must be replaced.

3. Install the spark arrester assembly with gasket; then secure with the three cap screws. Tighten to 48 in.-lb.

0735-505

3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.

CF104

Engine/Transmission Oil - Filter - Strainer 733-441A

OIL - FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely. 1. Park the ATV on level ground. 2. Remove the oil level stick/filler plug.

4. Remove the oil filter plug from the filter mounting boss (located on the front side of the transmission case) and allow the filter to drain completely. Install the plug and tighten securely. 5. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter. NOTE: Clean up any excess oil after removing the filter.

6. Apply oil to a new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely. NOTE: Install a new O-ring each time the filter is replaced.

2-8

7. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug.

400/H1/H2 Models

8. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 9. Turn the engine off and wait approximately one minute.

ATV-0100AA

13. Inspect the area around the drain plug and oil filter for leaks. STRAINER

10. Remove the oil level stick and wipe it with a clean cloth.

1. Remove the belly panel.

11. Install the oil level stick until the threads touch the engine case.

2. Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring (400/500).

NOTE: On the 400/H1/H2 models, the oil level stick should be threaded into the case for checking purposes.

12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark.

! CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “L” mark but not higher than the “F” mark. CC091D

500

3. Remove the two cap screws securing the strainer; then remove the strainer. NOTE: On the H1/H2 models, thoroughly clean any sealant from the oil strainer cap.

ATV-0100

CC163D

AT THIS POINT To check/service oil strainer, see Section 3.

2-9

4. Place the oil strainer into position beneath the crankcase and secure with the cap screws. Tighten securely. 5. Place the strainer cap into position on the strainer making sure the O-ring is properly installed (400/500) or silicone sealant is applied (H1/H2 models); then secure with the cap screws. Tighten securely.

AL677C

3. Drain the lubricant into a drain pan by removing in turn the drain plug from each.

CC091D

6. Install the belly panel.

Front Differential/Rear Drive Lubricant ATV0082A

Â&#x201E;NOTE: On the H2 models, the rear drive incorporates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock.

! CAUTION Any lubricant used in place of the recommended gear case lubricant could result in premature failure of the shock limiter. Do not use any lubricant containing graphite or molybdenum additives or other friction-modified lubricants as these may cause severe damage to shock limiter components.

When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the fill plug; the lubricant level should be 1 in. below the threads of the plug. If low, add SAE approved 80W-90 hypoid gear lubricant as necessary. To change the lubricant, use the following procedure. 1. Place the ATV on level ground. 2. Remove each fill plug.

737-651B

4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb. 5. Pour the appropriate amount of approved SAE 80W-90 hypoid gear lubricant into the filler hole. 6. Install the fill plugs. Â&#x201E;NOTE: If the differential/rear drive lubricant is contaminated with water, inspect the drain plug, fill plug, and/or bladder.

! CAUTION Water entering the outer end of the axle will not be able to enter the rear drive unless the seals are damaged.

2-10

Adjusting Clutch

(500 Manual Transmission) To adjust the clutch, use the following procedure. 1. Using an impact driver, remove the screws securing the cover and remove the cover. Account for the O-ring.

5. Rotate adjustment screw #1 clockwise 1/8 turn; then lock the jam nut securing adjustment screw #1. Â&#x201E;NOTE: At this point the clutch should be adjusted correctly. Test to ensure accurate adjustment.

6. Install the cover making sure the O-ring is properly positioned; then secure with the screws.

Steering Components The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. AM600D

2. Loosen the jam nuts securing adjustment screw #1 (forward) and adjustment screw #2 (rearward).

C. Steering post bearing assembly/bearing housing not broken, worn, or binding. D. Ball joints not worn, cracked, or damaged. E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing.

Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. CC037D

3. Rotate adjustment screw #1 counterclockwise until it stops.

A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn.

Suspension/Shock Absorbers/Bushings The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. CC038D

4. Rotate adjustment screw #2 alternately clockwise and counterclockwise to ensure free movement without binding; then lock the jam nut securing adjustment screw #2.

B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. 2-11

D. Shock absorber eyelets not broken, bent, or cracked. E. Shock absorber eyelet bushings not worn, deteriorated, cracked, or missing. F. Shock absorber spring not broken or sagging.

Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see Section 1).

CF135A

2. Pull the bulb straight out of the socket; then insert a new bulb.

Headlights/TaillightBrakelight Rotate the ignition switch to the lights position; the headlights and taillight should illuminate. Test the brakelight by compressing the brake lever. The brakelight should illuminate. HEADLIGHTS Â&#x201E;NOTE: The bulb portion of a headlight is fragile. HANDLE WITH CARE. When replacing a headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.

! WARNING Do not attempt to remove a bulb when it is hot. Severe burns may result.

CF132A

3. Insert the bulb socket assembly into the housing and turn it clockwise to secure. CHECKING/ADJUSTING HEADLIGHT AIM The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).

To replace a headlight bulb, use the following procedure. 1. Remove the wiring harness connector from the back of the headlight. 2. Grasp the bulb housing, turn it counterclockwise, and remove the bulb. 3. Install the new bulb into the housing and rotate it completely clockwise. 4. Install the wiring harness connector. TAILLIGHT-BRAKELIGHT ATV-0070C

To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. 2-12

Â&#x201E;NOTE: There should be an average operating load on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. 6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface. 7. Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam.

CF130A

Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light should be illuminated.

! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV.

If the reverse light does not illuminate when shifted to the reverse position, the switch may be faulty, the fuse may be blown, the bulb may be faulty, a connection may be loose or corroded, or the lever may need adjusting. To adjust, proceed to Adjusting Shift Lever. ADJUSTING SHIFT LEVER 1. Remove the seat; then remove the left-side engine cover. CD714A

Shift Lever

2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD.

CHECKING ADJUSTMENT

CF258A

CF238A

3. Tighten the jam nuts securely; then shift the transmission to each position and verify correct adjustment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.

2-13

Â&#x201E;NOTE: An E (Error) in the gear position icon indicates no signal or a poor ground wire connection in the circuit. Troubleshoot the harness connectors, gear shift position switch connector, gear shift position switch, and LCD connector.

Frame/Welds/Racks The frame, welds, and racks should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components. If replacement or repair constitutes removal, see Section 8.

Electrical Connections The electrical connections should be checked periodically for proper function. In case of an electrical failure, check fuses, connections (for tightness, corrosion, damage), and/or bulbs. If an electrical component needs to be tested for proper function, see Section 5.

Hydraulic Brake Systems

AL681

2. Compress the brake lever/pedal several times to check for a firm brake. If the brake is not firm, the system must be bled. 3. To bleed the brake system, use the following procedure. A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. B. Install and secure the cover; then slowly compress the brake lever/pedal several times. C. Remove the protective cap, install one end of a clear hose onto one FRONT bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake lever/pedal, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever/pedal. Repeat this procedure until no air bubbles are present.

CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake system, use the following procedure. 1. With the master cylinder in a level position, check the fluid level in the reservoir. On the hand brake if the level in the reservoir is adequate, the sight glass will appear dark. If the level is low, the sight glass will appear clear. On the auxiliary brake the level must be between the MIN and MAX lines on the reservoir. AF637D

738-420A PR377C

2-14

Â&#x201E;NOTE: During the bleeding procedure, watch the reservoir/sight glass very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.

4. To replace the brake pads, use the following procedure. A. Remove the wheel. B. Remove the cap screws securing the caliper holder to the knuckle; then remove the pads.

D. Repeat step C until the brake lever/pedal is firm. E. At this point, perform step B, C, and D on the other FRONT bleeder screw; then move to the REAR bleeder screw and follow the same procedure. 4. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present.

2 PR237

! CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces.

C. Install the new brake pads. D. Secure the caliper to the knuckle and/or axle housing with the cap screws. Tighten to 20 ft-lb.

INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows. PR377B

1. Remove a front wheel.

E. Install the wheel. Tighten to 40 ft-lb.

2. Measure the thickness of each brake pad. 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced.

5. Burnish the brake pads (see Burnishing Brake Pads in this section).

Burnishing Brake Pads Brake pads (both hydraulic and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure.

! WARNING PR376B

Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury.

Â&#x201E;NOTE: The brake pads should be replaced as a set. 2-15

1. Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then compress brake lever or apply the auxiliary brake to decelerate to 0-5 mph. 3. Repeat procedure on each brake system five times. 4. Adjust the auxiliary brake (if necessary). 5. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. CC546

Checking/Replacing V-Belt (Automatic Transmission)

REMOVING 1. Remove the right-side footrest (see Section 8). 2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover.

CC547

4. Remove the V-belt.

CC550 CD078

Â&#x201E;NOTE: Note the location of the main engine ground wire for installing purposes.

3. Remove the nut securing the movable drive face; then remove the face. Account for the spacer.

INSTALLING 1. Spread the faces of the driven clutch by pushing the inner face toward the engine while turning it counterclockwise (500) or threading in a push-bolt (400/H1/H2 models); then when the faces are separated, insert the belt and push down between the faces. 2. Place the V-belt into position over the front shaft.

2-16

NOTE: At this point, the push-bolt can be removed.

4. Rotate the V-belt and clutches until the V-belt is flush with the top of the driven clutch. 5. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb.

CC550

NOTE: The arrow on the V-belt should point forward.

3. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a nut (threads coated with red Loctite #271). Tighten the nut to 147 ft-lb (400), 72 ft-lb (500) or 165 ft-lb (H1/H2 models). CD083

NOTE: Make sure the main engine ground wire is installed and secured in the proper location.

6. Secure the front fender to the footrest with the two cap screws. Tighten securely. 7. Install the right-side footrest (see Section 8).

CC552

2-17

SECTION 3 - ENGINE/TRANSMISSION

TABLE OF CONTENTS Engine/Transmission ............................................... 3-2 Specifications (400)................................................. 3-2 Specifications (500)................................................. 3-3 Specifications (H1 Models)...................................... 3-4 Specifications (H2 Models)...................................... 3-4 Troubleshooting ....................................................... 3-5 400 Table of Contents ............................................. 3-9 500 (Automatic Transmission)/H1 Models Table of Contents ............................................... 3-50 500 (Manual Transmission) Table of Contents .... 3-102 H2 Models Table of Contents .............................. 3-166 3-1

Engine/Transmission

Specifications* (400)

This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame.

VALVES AND GUIDES Valve Face Diameter

(intake) 30.6 mm (exhaust) 27.0 mm

Valve/Tappet Clearance (cold engine)

(intake) 0.076-0.127 mm (exhaust) 0.152-0.203 mm

Valve Guide/Stem Clearance (max)

(intake) 0.04 mm (exhaust) 0.06 mm

Valve Guide/Valve Stem Deflection (wobble method)

(max) 0.35 mm

NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission.

Valve Guide Inside Diameter

5.000-5.015 mm

Valve Head Thickness

(intake) 2.03 mm (exhaust) 2.28 mm

NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions.

Valve Face/Seat Width (min)

(intake) 2.25 mm (exhaust) 2.55 mm

NOTE: Critical torque specifications are located in Section 1.

Valve Spring Free Length

Valve Stem Outside Diameter

(intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm

Valve Stem Runout

(max) 0.05 mm

Valve Seat Angle

(intake/exhaust) 45°

Valve Face Radial Runout

(max) 0.03 mm (min) 42.8 mm

(outer) 18.6-21.4 kg

Valve Spring Tension @ 32.5 mm

(41-47 lb)

CAMSHAFT AND CYLINDER HEAD

SPECIAL TOOLS

Cam Lobe Height (min)

A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description.

(intake/exhaust) 33.53 mm

Camshaft Journal/Cylinder Head Clearance(max) 0.081 mm Camshaft Journal Holder Inside Diameter

(right & center) 22.01-22.04 mm

Camshaft Journal Outside Diameter

(right & center) 21.959-21.980 mm

(left) 17.51-17.54 mm (left) 17.466-17.480 mm

Camshaft Runout

Description

p/n

(max) 0.03 mm

Rocker Arm Inside Diameter

12.000-12.018 mm

Clutch Sleeve Hub Holder

0444-007

Rocker Arm Shaft Outside Diameter

11.975-11.987 mm

Connecting Rod Holder

0444-006

Cylinder Head/Cover Distortion

(max) 0.05 mm

CYLINDER, PISTON, AND RINGS Crankcase Separator/Crankshaft Remover Driven Pulley Compressor

0444-009

Piston Skirt/Cylinder Clearance

0444-121

Piston Diameter 15 mm from Skirt End

0.060-0.073 mm 80.98-81.00 mm

(1st) 8.0 mm

Piston Ring Free End Gap (min) Driven Pulley Compressor

(2nd) 8.3 mm

0444-140 Bore x Stroke

81.0 x 71.2 mm

Magneto Rotor Remover Set

0444-206

Cylinder Trueness

(max) 0.01 mm

Oil Filter Wrench

0644-389

Piston Ring End Gap - Installed

(min) 0.15 mm

Piston Ring to Groove Clearance (max) (1st/2nd) 0.06 mm Piston Pin Puller

0644-328

Side Case Puller

0644-262

Side Case Puller

0644-365

Spanner Wrench

0444-153

Surface Plate

0644-016

Valve Clearance Adjuster

0444-078

V Blocks

0644-022

Piston Ring Groove Width

(1st) 1.01-1.03 mm (2nd) 1.21-1.23 mm (oil) 2.01-2.03 mm

Piston Ring Thickness

(1st) 0.97-0.99 mm (2nd) 1.17-1.19 mm

Piston Pin Bore

(max) 20.008 mm

Piston Pin

(min) 19.994 mm

CRANKSHAFT Connecting Rod (small end)

0.10-0.55 mm

Connecting Rod (big end width)

21.95-22.00 mm

Connecting Rod (small end deflection)

NOTE: Special tools are available from the Arctic Cat Service Parts Department.

(max) 20.021 mm

Connecting Rod (big end side-to-side)

Crankshaft (web-to-web) Crankshaft Runout

(max) 0.3 mm 60.8-60.9 mm (max) 0.03 mm

* Specifications subject to change without notice.

3-2

Specifications* (500)

CLUTCH (Manual Transmission) Clutch Release Screw

1/4-1/2 turn back

Drive Plate (fiber) Thickness

(min) 2.82 mm

Drive Plate (fiber) Tab

(min) 2.9 mm

Driven Plate (warpage)

(max) 0.1 mm

Clutch Spring Length

(min) 35.6 mm

Clutch Wheel Inside Diameter

140.0-140.2 mm

(intake) 30.6 mm (exhaust) 27.0 mm

Starter Clutch Shoe

No groove at any part

Clutch Engagement RPM

1700 ± 200

Valve/Tappet Clearance (cold engine)

(intake) 0.05-0.10 mm (exhaust) 0.17-0.22 mm

Clutch Lock-Up RPM

3700 ± 300

Valve Guide/Stem Clearance

(intake) 0.010-0.037 mm (exhaust) 0.030-0.057 mm

Primary Reduction Ratio

2.032 (63/31)

Secondary Reduction Ratio

1.133 (17/15)

VALVES AND GUIDES Valve Face Diameter

Valve Guide/Valve Stem Deflection (wobble deflection)

(max) 0.35 mm

Valve Guide Inside Diameter

5.000-5.012 mm

Valve Stem Outside Diameter

(intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm

Valve Stem Runout

(max) 0.05 mm

Valve Head Thickness

(min) 0.5 mm

Valve Stem End Length

(min) 2.3 mm

Valve Face/Seat Width

0.9-1.1 mm

Valve Seat Angle

(intake/exhaust) 45°

Valve Face Radial Runout

(max) 0.03 mm

Valve Spring Free Length

(min) 38.8 mm

Valve Spring Tension @ 31.5 mm

(outer) 18.6-21.4 kg (41-47 lb)

CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min)

(intake) 33.13 mm (exhaust) 33.20 mm

Camshaft Journal/Cylinder Head Clearance(max) 0.15 mm Camshaft Journal Holder Inside Diameter

(right & center) 22.012-22.025 mm (left) 17.512-17.525 mm

Camshaft Journal Outside Diameter

(right & center) 21.959-21.980 mm (left) 17.466-17.484 mm

Camshaft Runout

(max) 0.10 mm

Rocker Arm Inside Diameter Rocker Arm Shaft Outside Diameter

Final Reduction Ratio

(front/rear) 3.6 (36/10)

Secondary Transmission Reduction Ratio Gear Ratios

(low) 2.419 (22/23 x 27/17 x43/27) (high) 1.592 (43/27) (1st) (2nd) (3rd) (4th) (5th) (reverse)

Shift Fork to Groove (side clearance)

3.09 (34/11) 1.75 (28/16) 1.2 (24/20) 0.875 (21/24) 0.724 (21/29) 2.636 (24/11 x 29/24)

0.1-0.3 mm

Shift Fork Groove Width (#1 and #2) 5.5-5.6 mm (secondary transmission) 5.5-5.6 mm (reverse) 5.0-5.1 mm Shift Fork Thickness

(#1 and #2) 5.3-5.4 mm (secondary transmission) 5.3-5.4 mm (reverse) 4.8-4.9 mm

Thermostat Valve Opening Temperature

73.5-76.5°C (164-170°F)

Thermostat Valve Lift

Over 3 mm @ 90°C (194°F)

* Specifications subject to change without notice.

12.000-12.018 mm 11.973-11.984 mm

Cylinder Head Distortion

(max) 0.05 mm

Cylinder Head Cover Distortion

(max) 0.05 mm

CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance Piston Diameter 15 mm from Skirt End Piston Ring Free End Gap (min) Bore x Stroke

0.030-0.040 mm 87.465-87.480 mm (1st) 9.0 mm (2nd) 9.5 mm 87.5 x 82 mm

Cylinder Trueness

(max) 0.05 mm

Piston Ring End Gap - Installed

(min) 0.35 mm

Piston Ring to Groove Clearance (max)

(1st) 0.180 mm (2nd) 0.150 mm

Piston Ring Groove Width

(1st) 1.01-1.03 mm (2nd) 1.21-1.23 mm (oil) 2.51-2.53 mm

Piston Ring Thickness

(1st) 0.97-0.99 mm (2nd) 1.17-1.19 mm

Piston Pin Bore

(max) 23.03 mm

Piston Pin Outside Diameter

(min) 22.98 mm

CRANKSHAFT Connecting Rod (small end inside diameter)(max) 23.04 mm Connecting Rod (big end side-to-side) Connecting Rod (big end width) Connecting Rod (small end deflection) Crankshaft (web-to-web) Crankshaft Runout

0.10-0.65 mm 24.95-25.00 mm (max) 3 mm 71.02-71.22 mm (max) 0.08 mm

3-3

Specifications*

(H1 Models)

(H2 Models)

VALVES AND GUIDES

Valve Face Diameter

(intake) 31.6 mm (exhaust) 27.9 mm

Valve Face Diameter

(intake) 31.6 mm (exhaust) 27.9 mm

Valve/Tappet Clearance (cold engine)

(intake) 0.1016 mm (exhaust) 0.1524 mm

Valve/Tappet Clearance (cold engine)

(intake) 0.1016 mm (exhaust) 0.1524 mm

Valve Guide/Stem Clearance

(intake/exhaust) 0.013 mm

Valve Guide/Valve Stem Deflection (wobble method)

(max) 0.35 mm

Valve Guide Inside Diameter Valve Stem Outside Diameter

5.000-5.012 mm (intake/exhaust) 4.972-4.987 mm

Valve Guide/Stem Clearance

(intake/exhaust) 0.013 mm

Valve Guide/Valve Stem Deflection (wobble method)

(max) 0.35 mm

Valve Guide Inside Diameter Valve Stem Outside Diameter

5.000-5.012 mm (intake/exhaust) 4.972-4.987 mm

Valve Stem Runout

(max) 0.1 mm

Valve Stem Runout

Valve Head Thickness

(min) 2.3 mm

Valve Head Thickness

(min) 2.3 mm

Valve Stem End Length

(min) 3.97 mm

Valve Stem End Length

(min) 3.97 mm

Valve Face/Seat Width

(intake) 2.25 mm (exhaust) 2.60 mm

Valve Seat Angle

(intake/exhaust) 45° 15’-45° 30’

Valve Face/Seat Width

(max) 0.2 mm

Valve Face Radial Runout

Valve Spring Free Length

(min) 38.7 mm

Valve Spring Free Length

(outer) 19.0 kg (42 lb) (intake/exhaust) 33.53 mm

Camshaft Journal/Cylinder Head Clearance

(max) 0.04 mm

(intake/exhaust) 45° 15’-45° 30’ (max) 0.2 mm (min) 38.7 mm

Valve Spring Tension @ 31.5 mm

CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min)

(intake) 2.25 mm (exhaust) 2.60 mm

Valve Seat Angle

Valve Face Radial Runout Valve Spring Tension @ 31.5 mm

(max) 0.1 mm

(outer) 19.0 kg (42 lb)

CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min)

(intake/exhaust) 33.53 mm

Camshaft Journal/Cylinder Head Clearance

(max) 0.04 mm

Camshaft Journal Holder Inside Diameter

(right & center) 21.98-22.04 mm (left) 17.48-17.53 mm

Camshaft Journal Holder Inside Diameter

(right & center) 21.98-22.04 (left) 17.48-17.53 mm

Camshaft Journal Outside Diameter

(right & center) 21.96-21.98 mm (left) 17.47-17.48 mm

Camshaft Journal Outside Diameter

(right & center) 21.96-21.98 (left) 17.47-17.48 mm

Camshaft Runout

(max) 0.05 mm

Camshaft Runout

(max) 0.05 mm

Rocker Arm Inside Diameter

12.000-12.018 mm

Rocker Arm Inside Diameter

12.000-12.018 mm

Rocker Arm Shaft Outside Diameter

11.97-11.98 mm

Rocker Arm Shaft Outside Diameter

11.97-11.98 mm

Cylinder Head/Cover Distortion

(max) 0.05 mm

Cylinder Head/Cover Distortion

CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance

0.045 mm

Piston Skirt/Cylinder Clearance

Piston Diameter 15 mm from Skirt End (550)

97.948-97.962 mm

Piston Diameter 15 mm from Skirt End

Piston Diameter 12 mm from Skirt End (700)

101.930101.949 mm

Piston Ring End Gap (min)

Piston Ring Free End Gap

(1st/2nd) 12.5 mm

Bore x Stroke

92 x 82 mm - 550 102 x 82 mm - 700

Cylinder Trueness

(max) 0.01 mm

Piston Ring End Gap - Installed

(min) 0.36 mm (1st/2nd) 1.202-1.204 mm (oil) 2.01-2.03 mm

Piston Ring Thickness

(1st/2nd) 1.970-1.990 mm

Piston Pin Bore

(min) 22.99 mm

CRANKSHAFT Connecting Rod (small end inside diameter) Connecting Rod (big end side-to-side) Connecting Rod (big end width) Connecting Rod @ 150 mm (small end deflection) Crankshaft (web-to-web) Crankshaft Runout

(max) 23.021 mm

92 x 71.5 mm (max) 0.0075 mm

Piston Ring End Gap - Installed

25 mm (max) 0.3 mm 71 mm

(1st) 0.034 mm (2nd) 0.033 mm

Piston Ring Groove Width

(1st/2nd) 1.202-1.204 mm (oil) 2.501-2.503 mm

Piston Ring Thickness

(1st/2nd) 1.170-1.195 mm

Piston Pin Bore

(max) 20.012 mm

Piston Pin Outside Diameter

(min) 19.995 mm

CRANKSHAFT Connecting Rod (small end inside diameter) Connecting Rod (big end side-to-side) Connecting Rod @ 150 mm (small end deflection) Crankshaft (web-to-web)

(max) 20.021 mm 0.95 mm 21.95 mm (max) 0.3 mm 98 mm

Crankshaft Runout

(max) 0.03 mm

Oil Pump Gerotor Clearance

(max) 0.15 mm

(max) 0.03 mm

* Specifications subject to change without notice.

3-4

0.36 mm

Piston Ring to Groove Clearance (max)

Connecting Rod (big end width) 0.6 mm

91.949-97.959 mm (1st/2nd) 12.5 mm

Cylinder Trueness

(max) 23.0 mm

Piston Pin Outside Diameter

0.05 mm

Bore x Stroke

Piston Ring to Groove Clearance (max) (1st/2nd) 0.03 mm Piston Ring Groove Width

(max) 0.05 mm

CYLINDER, PISTON, AND RINGS

* Specifications subject to change without notice.

Troubleshooting Â&#x201E;NOTE: A Condition/Remedy marked with an asterisk (*) is for the manual transmission model only. Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. 2. 3. 4. 5. 6. 7.

Valve clearance out of adjustment Valve guides worn - seated poorly Valves mistimed Piston rings worn excessively Cylinder bore worn Spark plug seating poorly Starter motor cranks too slowly - does not turn

1. 2. 3. 4. 5. 6. 7.

Adjust clearance Repair - replace guides Adjust valve timing Replace rings Replace - rebore cylinder Tighten plug See Section 5 - Troubleshooting

Problem: Engine will not start or is hard to start (No spark) Condition Remedy 1. 2. 3. 4. 5. 6.

Spark plug fouled Spark plug wet Magneto defective CDI unit/ECU defective Ignition coil defective High-tension lead open - shorted

1. 2. 3. 4. 5. 6.

Clean - replace plug Clean - dry plug Replace magneto Replace CDI unit/ECU Replace ignition coil Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the carburetor/fuel injector) Condition Remedy 1. 2. 3. 4. 5.

Gas tank vent hose obstructed Carburetor float valve defective Fuel hose obstructed Fuel screens obstructed Fuel pump defective

Problem: Engine stalls easily Condition 1. 2. 3. 4. 5.

Spark plug fouled Magneto defective CDI unit/ECU defective Carburetor jets/fuel injector obstructed Valve clearance out of adjustment

Problem: Engine noisy (Excessive valve chatter) Condition 1. 2. 3. 4. 5.

Valve clearance too large Valve spring(s) weak - broken Rocker arm - rocker arm shaft worn Camshaft worn Valve tappets worn

1. 2. 3. 4. 5.

Clean vent hose Replace valve Clean - replace hose Clean - replace inlet screen - valve screen Replace fuel pump

Remedy 1. 2. 3. 4. 5.

Clean plug Replace magneto Replace CDI unit/ECU Clean jets/replace fuel injector Adjust clearance

Remedy 1. 2. 3. 4. 5.

Adjust clearance Replace spring(s) Replace arm - shaft Replace camshaft Replace tappets

Problem: Engine noisy (Noise seems to come from piston) Condition Remedy 1. 2. 3. 4.

Piston - cylinder worn Combustion chamber carbon buildup Piston pin - piston pin bore worn Piston rings - ring groove(s) worn

1. 2. 3. 4.

Replace - service piston - cylinder Clean chamber Replace - service pin - bore Replace rings - piston

Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 2. Sprockets worn 3. Tension adjuster malfunctioning

1. Replace chain 2. Replace sprockets 3. Repair - replace adjuster

3-5

Problem: Engine noisy (Noise seems to come from clutch) Condition * Remedy * 1. 2. 3. 4. 5.

Crankshaft splines - bearings worn Countershaft - hub splines worn Clutch plate teeth worn Driven - drive clutch plates distorted - broken Clutch dampers weak

1. 2. 3. 4. 5.

Replace crankshaft - bearings Replace countershaft - hub Replace clutch plate(s) Replace clutch plate(s) Replace dampers

Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 2. Lower rod-end bearing worn - burned 3. Connecting rod side clearance too large

1. Replace bearing 2. Replace bearing 3. Replace thrust washer(s)

Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. 2. 3. 4. 5.

Gears worn - rubbing Splines worn Primary gears worn - rubbing Bearings worn Bushing worn

1. 2. 3. 4. 5.

Replace gears Replace shaft(s) Replace gears Replace bearings Replace bushing

Problem: Engine noisy (Noise seems to come from secondary-transmission/left-side cover) Condition * Remedy * 1. Gears - shaft(s) worn 2. Bearing(s)/bushing(s) damaged

1. Replace gears - shafts 2. Replace bearing(s)/bushing(s)

Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. 2. 3. 4. 5. 6. 7.

Drive - driven bevel gears damaged - worn Backlash excessive Tooth contact improper Bearing damaged Gears worn - rubbing Splines worn Final driven shaft thrust clearance too large

Problem: Clutch slipping Condition * 1. 2. 3. 4. 5.

Release roller out of adjustment - loss of free-play Clutch springs weak Clutch shoes worn Pressure disc worn - distorted Clutch plates (driven - drive) distorted

Problem: Clutch dragging Condition *

1. 2. 3. 4. 5. 6. 7.

Replace gears Adjust backlash Adjust contact Replace bearing Replace gears Replace shaft(s) Replace thrust washer(s)

Remedy * 1. 2. 3. 4. 5.

Adjust clutch bolts 1 & 2 Replace springs Replace shoes Replace disc Replace plates

Remedy *

1. Clutch release roller out of adjustment - too much 1. Adjust clutch bolts 1 & 2 free-play 2. Clutch springs weak 2. Replace springs 3. Pressure disc - clutch plates distorted 3. Replace disc - plates 4. Clutch release mechanism worn - damaged 4. Adjust - replace mechanism

Problem: Transmission will not shift Condition * 1. 2. 3. 4. 5.

3-6

Gearshift cam broken Gearshift forks distorted Gearshift shaft worn Clutch release mechanism worn - damaged Gearshift linkage adjusted improperly

Remedy * 1. 2. 3. 4. 5.

Replace cam Replace forks Replace shaft Adjust - replace mechanism Adjust linkage

Problem: Transmission will not shift back Condition * 1. 2. 3. 4.

Reverse shift cam broken Shift shafts rubbing - sticking Gearshift forks distorted - worn Gearshift lever return spring broken - damaged

Problem: Transmission jumps out of gear Condition * 1. 2. 3. 4.

Shifting gears (driveshaft - countershaft) worn Gearshift forks distorted - worn Cam stopper spring (gearshift cam) weak Gearshift lever stopper pin worn

Remedy * 1. 2. 3. 4.

Replace cam Replace shafts Replace forks Replace spring

Remedy * 1. 2. 3. 4.

Replace gears Replace forks Replace spring Replace pin

Problem: Secondary-transmission will not shift or shift back Condition * Remedy * 1. 2. 3. 4. 5. 6.

Sliding dog broken - worn Gearshift fork broken - worn Shift lever out of adjustment Gearshift cam worn Cam stopper spring weak Gearshift fork shaft worn

1. 2. 3. 4. 5. 6.

Replace dog Replace fork Adjust lever Replace cam Replace spring Replace shaft

Problem: Engine idles poorly Condition

Remedy

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Valve clearance out of adjustment Valve seating poor Valve guides defective Rocker arms - arm shaft worn Magneto defective CDI unit/ECU defective Spark plug fouled - gap too wide Ignition coil defective Float out of adjustment Jets obstructed Pilot screw setting improper Fuel injector obstructed

Adjust clearance Replace - service seats - valves Replace guides Replace arms - shafts Replace magneto Replace CDI unit/ECU Adjust gap - replace plug Replace ignition coil Adjust float height Clean jets Adjust pilot screw Replace fuel injector

Problem: Engine runs poorly at high speed Condition

Remedy

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

High RPM â&#x20AC;&#x153;cut outâ&#x20AC;? against RPM limiter Valve springs weak Valve timing out of adjustment Cams - rocker arms - tappets worn Spark plug gap too narrow Ignition coil defective Float level too low Air cleaner element obstructed Fuel hose obstructed Fuel pump defective

Problem: Exhaust smoke dirty or heavy Condition 1. 2. 3. 4. 5. 6.

Oil (in the engine) overfilled - contaminated Piston rings - cylinder worn Valve guides worn Cylinder wall scored - scuffed Valve stems worn Stem seals defective

Shift into higher gear - decrease speed Replace springs Adjust timing Replace cams - arms - tappets Adjust gap Replace ignition oil Adjust float height Clean element Clean or replace hose Replace fuel pump

Remedy 1. 2. 3. 4. 5. 6.

Drain excess oil - replace oil Replace - service rings - cylinder Replace guides Replace - service cylinder Replace valves Replace seals

3-7

Problem: Engine lacks power Condition

Remedy

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Valve clearance incorrect Valve springs weak Valve timing incorrect Piston ring(s) - cylinder worn Valve seating poor Spark plug fouled Rocker arms - shafts worn Spark plug gap incorrect Carburetor jets/fuel injector obstructed Float level out of adjustment Air cleaner element obstructed Oil (in the engine) overfilled - contaminated Intake manifold leaking air Cam chain worn

Adjust clearance Replace springs Re-time valve gear Replace - service rings - cylinder Repair seats Clean - replace plug Replace arms - shafts Adjust gap - replace plug Clean jets - replace injector Adjust float height Clean element Drain excess oil - change oil Tighten - replace manifold Replace cam chain

Problem: Engine overheats Condition

Remedy

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

3-8

Carbon deposit (piston crown) excessive Oil low Octane low - gasoline poor Oil pump defective Oil circuit obstructed Gasoline level (in float chamber) too low Intake manifold leaking air Coolant level low Fan malfunctioning Fan switch malfunctioning Thermostat stuck - closed Radiator hoses - cap damaged - obstructed

Clean piston Add oil Drain - replace gasoline Replace pump Clean circuit Adjust float height Tighten - replace manifold Fill - examine system for leaks Check fan fuse - replace fan Replace fan switch Replace thermostat Clear obstruction - replace hoses

Table of Contents (400)

Removing Engine/Transmission.............................. 3-9 Top-Side Components........................................... 3-11 Removing Top-Side Components ......................... 3-11 Servicing Top-Side Components........................... 3-15 Installing Top-Side Components ........................... 3-23 Left-Side Components .......................................... 3-27 Removing Left-Side Components ......................... 3-27 Installing Left-Side Components ........................... 3-29 Right-Side Components ........................................ 3-30 Removing Right-Side Components....................... 3-30 Servicing Right-Side Components ........................ 3-34 Installing Right-Side Components......................... 3-35 Center Crankcase Components............................ 3-38 Separating Crankcase Halves............................... 3-39 Disassembling Crankcase Half ............................. 3-39 Servicing Center Crankcase Components............ 3-41 Assembling Crankcase Half .................................. 3-43 Joining Crankcase Halves..................................... 3-45 Installing Engine/Transmission.............................. 3-46

2. Remove the heat shield; then remove the gas tank (see Section 4). 3. Remove the oil fittings from the engine and account for two O-rings; then disconnect the oil temperature connector and cooling fan connector.

KC251

Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.

KC250

AT THIS POINT If the technicianâ&#x20AC;&#x2122;s objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame.

AT THIS POINT If the technicianâ&#x20AC;&#x2122;s objective is to service/replace left-side cover oil seals or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame.

Secure the ATV on a support stand to elevate the wheels.

KC249

4. Disconnect the speedometer sensor; then remove the E-clip securing the shift rod to the shift arm and disconnect the shift rod. Account for a bushing and flat washer.

! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

1. Remove the front rack, left and right footwells, and front body panel (see Section 8); then disconnect the negative battery cable from the battery.

3-9

6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring.

KC248

KC170

KC255

5. Remove the inlet air duct, air filter housing, and air silencer duct; then remove the carburetor and set aside leaving the throttle cable attached. KC238

7. Disconnect the gear shift position switch, starter cable, and engine ground cable; then disconnect the trigger coil and stator coil connectors.

KC235

KC228A

KC236

3-10

KC228B

8. Remove the front and rear V-belt cooling boots from the V-belt housing. 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts.

KC216

Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.

AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to removed from the frame for this procedure. KC242

Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft

KC243

10. Lift the rear of the engine/transmission and swing to the right; then tilt the assembly sufficiently to remove through the right-side frame opening.

NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compression stroke. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.

1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings.

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MD1264

Â&#x201E;NOTE: Keep the mounting hardware with the covers for assembly purposes.

MD1245

4. Remove the cam chain tensioner pivot cap screw and washer.

2. Remove the valve cover cap screws. Note the rubber washers on the four top-side cap screws; remove the valve cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins.

MD1251

5. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft.

CF007A

MD1136

MD1354A

3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two cap screws securing the cam chain tensioner assembly. Remove the tensioner assembly and gasket.

MD1137

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